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Blast furnace
The document describes the process of forming iron and steel using a blast furnace. It involves the following key steps: 1. Sinter is added to the top of the blast furnace. Air is blasted into the bottom to fuel reactions that melt the iron out of the sinter. 2. Molten iron collects at the bottom of the furnace and is tapped out periodically. Slag floats on top and is also tapped out. Wasted gases exit from the top. 3. The iron produced contains carbon and impurities, making it cast iron. Steel is made by removing carbon from cast iron through oxidation, then adding other metals to produce alloys with specific properties.
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Blast furnace
- 1. The Formation ofIron and Steel The Blast Furnace
- 2. Step 1 -the formation of sinter
- 3. Step 2 -the Blast Furnace The outer case is a water cooled steel casing that provides the main support for the 30 m high furnace.
- 4. Step 2a -the Blast Furnace The sinter is added through a hopper at the top of the Blast Furnace. The design of the hopper stops gases escaping through the top as sinter is added.
- 5. Step 2b -the Blast Furnace The inner lining is made of insulating bricks, designed to reduce heat loss through the outer walls of the furnace.
- 6. Step 2c -the Blast Furnace The furnace is run continuously for up to 2 years. Air is blasted in at the bottom at point A. AA
- 7. Step 2d -the Blast Furnace When running continuously, iron is run out through a tap hole, drilled into the furnace at the bottom, B. AA B
- 8. Step 2e -the Blast Furnace Slag is less dense than iron and floats on the surface. Slag is run out through a second tap hole labeled C. AA B C
- 9. Step 2f -the Blast Furnace Wasted gases pass out through the top of the furnace, at point D. The hot gases are used to pre-heat the incoming gases at A. AA B C D D
- 10. Step 2g -the Blast Furnace Iron that forms in the furnace melts at the temperature of 1700 °C. The iron drips down to the bottom. AA B C D D
- 11. Equations for thereactions carbon oxygen carbon dioxide + → C(s) O2(g) CO2(g)+ → This reaction is exothermic and provides the energy needed to heat the furnace.
- 12. Equations for thereactions carbon dioxide carbon carbon monoxide + → CO2(g) C(s) 2CO(g)+ → The carbon monoxide produced from the carbon dioxide, is the reducing agent which takes the oxygen from the iron(III) oxide.
- 13. Equations for thereactions Iron(III) oxide carbon monoxide iron carbon dioxide + +→ Fe2O3(s) 3CO(g) 2Fe(s) 3CO2(g)+ +→ The iron(III) oxide is reduced. Reduction means the iron(III) oxide loses oxygen. The Fe3+ ions gains 3 electrons to form Fe atoms.
- 14. Cast Iron The ironfrom the furnace contains up to 5 % carbon along with other impurities. Cast iron is brittle and has only limited uses such as engine blocks.
- 15. Cast iron intosteel Steel is made from cast iron. The carbon is removed by passing oxygen through the molten cast iron. When the carbon content has fallen to the required level, other metals are added to form a number of alloys.
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